6.

Heat Setting: The process of imparting dimensional stability of fibres or yarns with successive heating and cooling
in dry and moist conditions is called heat 910 16h 240
setting.
Object-
 To make the yarn, fabric dimensionally stable.
 To remove shrinkage of fabric.

Chemical and physical modification of man-made fiber production:

1. Adding substance to the polymer:

• Delusturing agent: Titanium Oxide
• Optical brightening agent: Derivatives of stilbene, paraxilene, dibenzophenon
• Light Stabilizer: Polyhydroxybenzophenon
• Heat stabilizer: tris(2,3-dibromo propyl phosphate)

2. Changing size and shape of spinneret hole:

• For carpet fibers: heavy denier from 15~24 denier
• For dilobal fibers
• For trilobal fibers
• For multilobal fibers
Additives:
Additives are chemical compound which are added to fiber forming polymer before polymerization reaction or
before spinning to change the properties of liber and improve its performance! Additives can not be used when
filaments come out from the spinneret.

Classification of additives:
1. Delusturing agent: These are used to reduce transparency, increase whiteness and to prevent undesirable
lusture in the fiber. Titanium oxide(TiO2) is widely used as delusturing agent.
2. Optical brightening agent: They are colorless dyes) They absorb invisible ultra violet radiation and reflect
this in the range of visible blue light. This causes the textile ml to reflect more blue light and makes the ml
whiten and brighter. Example: derivatives of stilbene, paraxilene, dibenzophenon.
3. Light stabilizer: polyhydroxy benzophenone
4. Heat stabilizer: tris (2,3 dibromo propyl phosphate)
Spin finish:
Spin finishes are the lubricants which provides surface lubricating. plasticizing and static protection to man-
made fiber.

Objects-
• To lubricate the yarn
• To reduce static electricity
• To increase the cohesion of the yarn
• To plasticize the yarn

Different types of spin finishes:

1. Lubricants: used to control the friction of the fiber. Example: oils, polyglycols, ester of fatty acid.
2. Plasticizers: plasticizers make the fiber more flexible by reducing the glass transition temp. and also
reduce brittleness. Example: dibutyl, silicate esters, silicate.
3. Antistatic agents: antistatic agents are hygroscopic chemicals which can conduct the static charge from
fiber to air or earth to improve dielectric constant and to reduce co-efficient of friction. Example:
Inorganic
salt(lithium chloride), ester of fatty acid (butyl stearate)
Properties/requirements of spin finishes:

1. It should lubricate the filament for controlling the friction

2. It should have anti static property
3.It should plasticize the filament
4.It should not be oxidized in the air
5. It should not be carcinogenic
6. It should be non toxic
7.It should be chemically inert
8. It should be cheap and easily available
Methods of Spinning: Spinning method based on physical and chemical properties of polymer:

There are also 3 special types of spinning:

a) Reaction spinning
b) Emulsion Spinning
c) Fibrillated Spinning
Spinning principle:
• The prepared polymer in form of viscose fluid is forcely fed to multiple slits of spinneret.
• In the way to spinneret, these are purified to remove impurities(by filter).
• Thus large number of streams like the shower are extruded from the spinneret which are called filament.
Number of filaments depend on number of slits of spinneret.
• At last the filaments are strengthen to solid form by several process. Ex: coolant air, vaporizing,
extraction
• Finally we het undrawn yarn which is to be drawn or stretched in the next subsequent
drawing/stretching process.

Factors of spinning:
• Melting point of fiber
• Decomposition temperature of fibers.
 Melt spinning:
•Oldest procedure to make filament is melt spinning.
•Used when polymer on melting give a viscous liquid without decomposition.
•Polymer must have a melting point and should not degrade when heated.
•Melt spinning is the conversion of a molten polymer into filaments by extrusion and subsequent
cooling of extrudes.
Examples: Nylon, polyester, polypropylene etc are made from melt spinning process.
polymer Melting temperature

Nylon-6 220°
Nylon-6,6 264°
PET 264°

Working principle:
• The polymer in the form of hot molten material (method by melted) is forcely fed to the spinneret.
• In the way to spinneret, the solution is purified by filter.
• Thus the filaments are extruded from spinneret.
• At last the filaments are strengthen by coolant air to solid form.
• Finally we get undrawn yarn for next subsequent process “Drawing”.
Requirement:
• The melting point of polymer should be less than its decomposition temperature.
• The polymer shouldn’t be volatile.

Advantage of melt spinning:

• Can be used for both staple and continuous filament.
• No need of solvent and chemical , and its recovery.
• Higher production rate can be adjusted with minor change.
• Simple and economical process.

Disadvantage of melt spinning:

• Only limited polymer (PET, polyester, polyamide) can undergo melt spinning.
• Structural development in fiber is poor, because of fast solidification rate.
• Because of inadequate structural development optimum strength can’t be achieved. So need further
drawing process.
• Accurate temperature control is very critical for uniform and optimum properties.
DRY SPINNING Steps involved in dry spinning:

•Solution preparation (polymer + solvent): in dry spinning, a volatile solvent is used to dissolve the raw
materials and form a spinning solution/ dope solution. The polymer concentration in the dope ranges from 20
to 30%. Higher polymer concentration results in higher solution viscosity and difficulties in material handling.
The polymer solution is heated to a higher temperature to reduce dope viscosity.
•Then the solution is transferred to the spin block and purified by filter.
•The solution is extruded through a spinneret into a warm air chamber where the solvent evaporates,
solidifying the fine filaments.
•Finally, the filament yarn is immediately wound onto bobbins or is further treated for certain desired
characteristics or end use.
•Application of spin finish for lubrication and antistatic effect.
•Collection of filaments in take-up bobbin.
Example: Acetate, tri-acetate and some acrylic, mod acrylic, spandex and nylon( PVC, PVA) fibers.
Polymer solvent

Cellulose acetate Acetone

Cellulose tri-acetate Methyl chloride

PVC Acetone

PAN, PU DMF
Advantages of dry spinning:
• It is suitable for heat sensitive polymer.
• Higher spinning speeds can be easily achieved.
• The post spinning operation is simple.
• Moderate concentration of [polymer is required.
• It is relatively flexible process and spinning conditions can be modified.

Disadvantages of dry spinning:

• Flammable solvent hazards.
• Solvent recovery is required.
• Additional post spinning operation is required for complete removal of solvent.
• Difficult to achieve exact cross-section of fiber.
• Slow(200-400 yds/min)
WET SPINNING:
Example: acrylic, rayon, mod acrylic, spandex, PAN, PVA

Working process:
•At first, the solid polymer and solvent is dissolved in the solution vessel to form the spinning solution which
forcefully fed to the filter.
•In the way to spinneret, it’s been purified by filter.
•Thus, the filaments are extrude from the spinnerets.
•At last, the filaments are strengthened to solid form by extraction of solvent instead of vaporizing used in dry
spinning. The extraction of solvent is done simply by washing it out or by chemical reactions between the polymer
solution and the reagent in the spinning bath.
•Finally we get, the undrawn yarn for next process “Drawing”.

fiber solvent Co-agulant

PVA water Aqueous NaOH

PAN 60% ZncI₂ + DMC 40% Zncl₂ + Aqueous DMC

Advantages of wet spinning:
• It can be used for most polymers, even melt-spun polymers like polyethylene, nylon, polypropylene to obtain
high molecular orientation.
• Fibers can attain maximum strength, comparable with the maximum theoretical strength, particularly for flexible
polymers. Melt spinning process can not result in maximum theoretical strength.

Disadvantage of wet spinning:

• The bulk production is low
• One or more bath is required for complete removal of the solvent from the fibers.
• Post spinning operation are lengthy.
• Because of lengthier process, it is costly.
• The achievement of exact fiber cross section is difficult due to inward and outward mass transfer process.
 Difference between Melt, Dry and Wet spinning:
SL Subject Melt spinning Dry spinning Wet spinning

1 produced Staple & Only filament Staple& filament

fiber filament
2 Strengthened Coolant air Hot air Extraction
by (filaments) vaporizing of solvent
3 Solvent used Not required volatile solvent Nonvolatile solvent is
is required required.

4 Spinneret 2-many 300 - 900 20,000-

Slits thousands 75,000
number
5 Spinning speed 2500 - 3000 2500 - 3000 150-300
ft/min ft/min ft/min
6 Environmental Hazard Non Toxic Toxic Toxic
7 Investment cost Low High Low
8 Production High Low Low high
9 Heat of High Very high Low
Spinning
10 Usage PET, polyamide Cellulose Acetate, cellulose, Proteins
or Cellulose Triacetate, Polyaerylonitrile
Application PVC, PVA
or Example